Pallet cap

ABSTRACT

A pallet cap for transporting stacked loads of commercial goods is disclosed. The pallet cap comprises a generally rectangular frame having a plurality of peripheral downwardly extending flanges and top rim portions integrally defined by flange corners. The plurality of top rim portions has on an opposite side interior step portions used for holding the load of packaged goods together on a pallet for transport and storage. Additionally, the top rim and associated step portions further define a cutout top center portion used to examine expiration dates displayed on the side of the stacked goods. For ease of transportation and storage, the pallet cap is formed by assembling a flat paperboard strip of a predetermined length and width wherein by folding and bending the strip along predefined longitudinal and transverse score lines the pallet cap of the present invention is created.

TECHNICAL FIELD

The present invention relates to a pallet cap or cover for covering a top side or bottom side of a load on a pallet, and to a method of forming the pallet cap.

BACKGROUND ART

In the transportation industry, pallets are used for shipping commercial items in bulk and are generally made of wood or plastic. In most cases the pallet comprises a skid and the items to be shipped are stacked on top of the skid and held in place by plastic wrapping or metal straps. In order to stabilize and secure the load on the pallet skid a pallet cap is utilized which rests on the top of the load and is typically secured there by tightly wrapping plastic about the whole assembly. Additionally, the pallet cap also provides a surface on which another skid may be placed.

Prior art pallet caps are generally constructed as either a square or rectangular frame in order to provide a step portion along the inner perimeter of the frame. This provides a surface against which the packaged goods when stacked are held together on top of a pallet for storage and/or transportation. Prior art pallet caps are typically manufactured as a wooden frame made of four thin pieces of wood joined to form a square or rectangular frame. Additionally, four metal plate brackets are provided with each bracket overlapping the adjacent ends of two pieces of wood and are secured to the wood using screws, nails or glue.

These type of pallet caps are expensive to make due to the increasing cost of wood and are expensive to recycle since they are made of wood and metal. Another problem with these this type of pallet cap is that the pallet caps themselves cannot be stored flat as the right angle preformed corner sits upright and hence, they require considerable storage space. This increases storage costs. Also, the formation of the rigid, screwed, nailed or glued corners adds to the cost of the pallet caps. Often, pallet caps are discarded after one or several usages making them expensive to use. The subject invention solves the cost of pallet caps by making them cost effective in manufacturing and due to use of recycled materials beneficial to the environment.

Accordingly, there is a need for a new and improved pallet cap that is inexpensive to manufacture, defines a top square cutout portion for load examination, may be stored flat before and after use, and after assembly will remain on the top of the load prior to the load being wrapped in plastic.

SUMMARY OF THE INVENTION

A pallet cap for transporting stacked loads of commercial goods is disclosed. The pallet cap comprises a generally rectangular frame having a plurality of peripheral downwardly extending flanges and top rim portions integrally defined by flange corners. The plurality of top rim portions has on an opposite side interior step portions used for holding the load of packaged goods together on a pallet for transport and storage. Additionally, the top rim and associated step portions further define a cutout top center portion used to examine expiration dates displayed on the side of the stacked goods. For ease of transportation and storage, the pallet cap is formed by assembling a flat paperboard strip of a predetermined length and width wherein by folding and bending the strip along predefined longitudinal and transverse score lines the pallet cap of the present invention is created.

DESCRIPTION OF THE DRAWINGS

In accordance with these and other objects, which will become apparent hereinafter, the instant invention will now be described with particular reference to the accompanying drawings.

FIG. 1 is a perspective top view of an assembled pallet cap forming a pallet cover for use with stacked goods on a pallet in accordance with a preferred embodiment of the invention;

FIG. 2 is a perspective bottom view of an assembled pallet cap forming a pallet cover for use with stacked goods on a pallet in accordance with a preferred embodiment of the invention;

FIG. 3 is a plan view of a flat paperboard sheet which after assembly forms the pallet cap shown in FIGS. 1 and 2;

FIGS. 4 through 8 are plan views illustrating the steps of folding and bending the flat paperboard strip to form the pallet cap of the present invention; and

FIG. 9 is a perspective view of the pallet cap used with stacked goods on a pallet in accordance with the present invention.

DESCRIPTION OF EMBODIMENTS

Referring now to FIGS. 1 and 2 there is shown a pallet cap 10 having a generally rectangular shape comprising four peripheral extending flange portions 14, 16, 18 and 20 and four top rim portions 14 a, 16 a, 18 a and 20 a which are integrally defined by flange corners 22, 24, 26 and 28. Furthermore, the four top rim portions 14 a, 16 a, 18 a and 20 a of pallet cap 20 also defines interior step portions 14 b, 16 b, 18 b and 20 b wherein the top rim and associated step portions, respectively further define a cutout center portion 12. The pallet cap 10 is preferably constructed of a soft flexible material, such as paperboard, cardboard or the like.

Referring now to FIGS. 3 through 8, the pallet cap 10 is formed and assembled starting with a flat paperboard or cardboard strip 19 of a predetermined length and width which in a preferred embodiment is 182 inches in length and 8 inches in width. As shown in FIG. 3 the flat paperboard or cardboard strip 19 is longitudinally scored 30 down the center along the complete length of strip 19 thereby providing a fold line for bending the strip 19 upwardly which defines the longitudinal flange portions 14, 16, 18 and 20 against one surface of the strip. However, before this bending operation is performed, the strip 19 is scored transversely to define both the fold lines for the corners 22, 24, 26 and 28 and four top rim portions 14 a, 16 a, 18 a and 20 a of pallet cap 20.

Referring once again to FIGS. 3 and 4, after bending the strip 19 the longitudinal score line 30 defines the longitudinally extending flange portions 14, 16, 18 and 20, wherein each flange portion is scored in alignment with each of the transverse score lines used to create the flange corners 22, 24, 26 and 28, respectively during assembly as will be more fully described below. It should be noted that there are four flanges and four rim portions defined by bending one integral flat strip 19 wherein the first and third flange portions 14, 18 and corresponding rim portions 14 a and 14 b are both 40 inches long and are 4 inches each in width. The second flange portion 16 and corresponding rim portion 16 a are 48 inches long and are once again 4 inches each in width. Lastly, the fourth flange portion 18 and corresponding rim portion 18 a are 54 inches long divided into 48 inches and 6 inches in length at score line 28 and 4 inches each in width.

After the strip 19 has been scored and bent as illustrated in FIG. 4, the next step is to fold the strip 19 on the 4 inch scoring mark indentation between the 40 inch section end of the first flange portion 14 and the 48 inch section of the second flange portion 16 to a 90 degree angle thereby creating flange corner 22 and step portions 14 a and 16 a, respectively as shown in FIG. 5. Next, fold the strip 19 on the 4 inch scoring mark indentation between the end 40 inch section and the center 48 inch of the second flange portion 16 and the center 48 inch section of the third flange portion 18 to a 90 degree angle thereby creating flange corner 24 and step portions 16 a and 18 a, respectively as shown in FIG. 6.

After the strip 19 has been folded twice as illustrated in FIGS. 5 and 6, the next step is to fold the strip 19 on the 4 inch scoring mark indentation between the 48 inch section end of the third flange portion 18 and the 54 inch section of the fourth flange portion 20 to a 90 degree angle thereby creating flange corner 26 and step portions 18 a and 20 a, respectively as shown in FIG. 7. Lastly, the remainder of strip 19 is now folded on the last remaining 4 inch scoring mark indentation between the end 58 inch section of the fourth flange portion 20 and the 6 inch tab section 20 c to a 90 degree angle. Insert the slit 20 d in the 6 inch tab down into the slit 14 d in the 40 inch side of the first flange portion 14 d thereby creating the pallet cap of the present invention. Referring now to FIG. 9, the pallet cap 20 may be used on the top and if desired additionally on the bottom of a pallet 32 for holding a load 34 of stacked goods and may be further secured by tightly wrapping plastic about the whole assembly. The center defined cutout 12 may be used to examine an expiration date (not shown) displayed on the side of the packaged goods which are stacked to produce load 34

It has been found that the pallet cap of the present invention may be in the range of 20 to 25 percent lighter in weight than comparable pallet caps of the type conventionally used in the prior art. This lighter weight is desirable from the standpoint that it results in a material saving, which reduces the cost of the pallet cap, as compared to the prior art. Also, the bended, unencumbered corners which are created by folding a single paperboard strip to create this pallet cap has proven to be advantageous over prior-art constructions wherein overlapping or other means of securement must be provided at each corner of a frame creating similar pallet caps. Although the pallet cap is shown in the drawings as being of rectangular configuration, it will be understood that this invention may be used in connection with other configurations as well.

It is contemplated for embodiments of the invention to extend to individual elements and concepts described herein, independently of other concepts, ideas or system, as well as for embodiments to include combinations of elements recited anywhere in this application. Although illustrative embodiments of the invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments. As such, many modifications and variations will be apparent to practitioners skilled in this art. Accordingly, it is intended that the scope of the invention be defined by the following claims and their equivalents. Furthermore, it is contemplated that a particular feature described either individually or as part of an embodiment can be combined with other individually described features, or parts of other embodiments, even if the other features and embodiments make no mention of the particular feature. Therefore, the absence of describing combinations should not preclude the inventor from claiming rights to such combinations. 

What is claimed is:
 1. A pallet cap comprising: a frame comprising a plurality of peripheral downwardly extending flange and top rim portions integrally defined by flange corners; wherein said plurality of top rim portions has on an opposite side interior step portions; wherein said top rim and associated step portions further define a cutout top center portion.
 2. The pallet cap according to claim 1 wherein said frame may be formed by assembling a flat strip of material by folding and bending the strip along longitudinal and transverse score lines.
 3. The pallet cap according to claim 1 wherein said frame is made from paperboard.
 4. The pallet cap according to claim 1 wherein said frame is assembled from flat strip of paperboard by six fold and bending steps.
 5. The pallet cap according to claim 1 wherein said cutout top center portion is sufficiently large to read expiration dates on stacked goods placed on a pallet.
 7. The method of making a pallet cap comprising the following steps: A. cutting and scoring an elongated strip of flexible material; B. folding said strip along a longitudinal score line located down a centerline of said strip; C. bending said folded strip along transversely defined score lines for creating corners and top rim and flange portions; F. inserting said strip end into a slit defined on an opposite end of said strip for completing the assembly of the pallet cap.
 8. The method of claim 7 further characterized in that said strip is constructed from paperboard.
 9. The method of claim 8 further characterized in that the assembly of said flat strip defines a cutout top center portion.
 10. The method of claim 8 further characterized in that said flange portions are of sufficient downward length to securely hold stacked goods when placed on a pallet. 